Belzona 1321 – NICCO ENGINEERING SERVICES LIMITED

DM Water Drainage Line Reclamation Using Belzona Solutions

admin — Mon, 17 Nov 2025 10:00:35 +0000

The DM (Demineralized) Water Drainage Pipeline in a critical utility section had suffered extensive corrosion damage due to prolonged exposure to water and environmental factors. Upon inspection, NESL’s service engineers identified severe metal loss and pitting corrosion on both the inner and outer surfaces of the carbon steel line.

Challenge

Replacing the damaged section of the drainage line would have required shutdown of the water treatment unit, extensive cutting, welding, and hydro-testing—making it a costly and time-consuming process. The client therefore sought a cold-applied repair solution that could:

Be executed in situ while the plant remained in operation.
Provide long-term corrosion protection against continuous exposure to DM water.
Eliminate the need for hot work and replacement.

Proposed Solution

NESL recommended a Belzona polymeric repair and protection system comprising:

Belzona 1161 (Super UW-Metal) – for rebuilding and profiling the heavily pitted surface.
Belzona 1321 (Ceramic S-Metal) – as a corrosion-resistant topcoat providing a smooth, hydrophobic finish.
Belzona 9341 Reinforcement Sheet – used to strengthen the repair in high-stress or structural areas.

Application Procedure

All work was carried out by NESL’s certified Belzona applicators under live plant conditions.

Surface Preparation

The pipeline surface was mechanically cleaned using power tools and abrasive blasting (where accessible) to achieve a minimum SA 2.5 surface cleanliness and a surface roughness of 75–125 microns.
All corrosion products and loose scales were removed, and the area was thoroughly degreased using Belzona 9111 (Cleaner/Degreaser).

Rebuilding of Metal Loss

Deep pitting and wall thinning were rebuilt using Belzona 1161.
The material was mixed in the prescribed ratio and applied using a steel spatula to rebuild the original profile of the pipeline.
In areas where the pitting exceeded 3 mm depth, Belzona 9341 reinforcement sheet was embedded into the first layer to provide additional mechanical strength.

Surface Smoothing and Coating

After initial curing, the surface was lightly abraded to achieve a smooth transition.
A full overcoat of Belzona 1321 (Ceramic S-Metal) was then applied in two coats, with contrasting colors to ensure uniform coverage and desired DFT (Dry Film Thickness).
This coating provided an impermeable, corrosion-resistant barrier against DM water and environmental moisture.

Quality Checks and Curing

Coating thickness was verified using a DFT gauge, ensuring consistent coverage (minimum 500 µm total).
After full cure, a spark test was conducted to confirm coating integrity.
The system was then allowed to cure before exposure to service conditions.

Results

The Belzona-applied section was reinstated within 24 hours, avoiding any production loss.
The pipeline integrity was fully restored without any hot work or welding.
The client achieved significant cost savings—over 70% compared to replacement—and gained a durable corrosion protection system expected to last over 5 years in continuous service.

Conclusion

The use of Belzona 1161 & 1321 with 9341 reinforcement provided a cold, safe, and efficient repair method for the DM water drainage line.

This case highlights how NESL’s expertise in polymeric repair technology enables industrial plants to restore critical assets without costly shutdowns, ensuring operational continuity, safety, and sustainability.

Cavitation Repair and Protection of Coastal Sathwa Vessel’s Stern Pipe

admin — Mon, 04 Nov 2024 07:45:55 +0000

In the maritime industry, corrosion control is a constant challenge, especially for vessels exposed to harsh seawater environments. This case study covers the successful repair and protection of the stern pipe of the Coastal Sathwa vessel, demonstrating the importance of advanced repair materials and processes.

Corrosion & cavitation challenge

The stern pipe of the Coastal Sathwa experienced significant pitting corrosion, which is common in submerged metal parts of vessels due to constant exposure to seawater. The affected surface had approximately 150-200 pits with depths ranging from 1-3 mm. Pitting, if not addressed promptly, can escalate to severe structural damage, impacting vessel safety and performance.

Solution and Approach

The repair strategy focused on pit filling, surface rebuilding, and protective coating. The following products were used:

Belzona 1311 (Ceramic R-Metal): A two-component epoxy used for rebuilding the pitted surface. It features a paste-grade system suitable for filling and leveling eroded metal areas, restoring the surface to its original contour.

Belzona 1321 (Ceramic S-Metal): This two-component epoxy coating was applied after surface preparation to provide corrosion and erosion resistance. It is designed for continuous immersion in seawater and offers a solvent-free, highly durable protective layer.

Application Procedure

The application process involved meticulous surface preparation and coating:

Surface Preparation: Achieved using SA 2.5 grit blasting, followed by cleaning and degreasing to ensure a contaminant-free substrate. This stage is crucial to maximize adhesion of the repair and coating materials.

Rebuilding Phase: Belzona 1311 was applied to fill the pits, reshaping the metal surface. After curing, the surface was smoothened for the next phase.

Coating Phase: After surface frost blasting (20-50 microns), Belzona 1321 was applied uniformly, ensuring complete coverage and the specified thickness to withstand the marine environment.

The Outcome

The repair was completed within a single day, demonstrating efficient use of resources and time. Post-application inspections confirmed that the restored stern pipe met performance expectations, with enhanced protection against future corrosion and erosion.

Key Takeaways

Material Choice: Selecting high-performance epoxy systems like Belzona 1311 and 1321 ensures lasting protection and reduces maintenance frequency.

Surface Preparation: Proper surface preparation is crucial for effective adhesion and long-term durability of the protective coatings.

Efficiency: The project was completed within 24 hours, demonstrating the effectiveness of fast-curing materials in critical ship repair applications.

Final Thoughts

The successful rehabilitation of the Coastal Sathwa’s stern pipe highlights how proactive corrosion management can extend the life of maritime assets, reduce downtime, and improve safety. By using innovative epoxy solutions and adhering to best practices in surface preparation and application, we achieved a reliable, long-term repair solution.

If you have similar challenges or would like to discuss how advanced polymer technologies can benefit your projects, feel free to connect or leave a comment below!

Reviving Corroded Fan Blades: A Belzona 1321 Case Study at a Leading Cement Plant in India

admin — Mon, 16 Oct 2023 07:10:47 +0000

The cement industry in India is a vital contributor to the country’s infrastructure development, but it faces numerous challenges in maintaining and optimizing its operational machinery. One such challenge encountered by a prominent cement plant in India was the corrosion of fan blades. The client sought a cold repair solution that would be both economical and allow for the shortest possible outage window to minimize production disruption.

The Problem:

The cement plant’s fan blades had suffered extensive corrosion due to constant exposure to a chemical environment, which compromised their structural integrity. This corrosion posed a significant threat to the efficient operation of the plant’s cooling system and necessitated immediate attention.

Belzona 1321 Cold Repair Solution

After a thorough assessment, our experienced service engineer identified the fan blades’ corroded surface as the primary issue. In cases where metal surfaces are in constant contact with harsh chemicals, Belzona 1321 proved to be an effective and economical solution for preventing further deterioration and restoring the metal surface integrity.

Surface Preparation and Application of Belzona

Surface Preparation: The corroded fan blades, which were made of carbon steel, were meticulously prepared to remove the damaged and corroded layers. This preparation was achieved using readily available hand tools until a smooth and clean surface was attained. Proper surface preparation is vital for the success of any Belzona application.

A carefully measured and mixed quantity of Belzona 1321, a two-component cold-curing epoxy, was applied to the prepared fan blades. The application was conducted with precision, ensuring complete coverage of the affected areas.

The coating was allowed to cure for a specified period. The quick curing time minimized the downtime, ensuring a swift return to operational status.

The Result and Advantages:

Belzona 1321 proved to be highly effective in restoring the integrity of the fan blades. The cement plant experienced several benefits:

Corrosion Prevention: Belzona 1321 created a durable and protective barrier against further corrosion, extending the fan blades’ lifespan.

Economical Solution: The cost of using Belzona 1321 for this cold repair was considerably lower than the expense of replacing the fan blades or using traditional repair methods.

Shortened Outage Window: The rapid curing time of Belzona 1321 allowed the cement plant to minimize production downtime, ensuring a quicker return to full operational capacity.

Enhanced Reliability: With the fan blades restored to their original condition, the cooling system’s efficiency and overall plant reliability were significantly improved.